Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
Page 5: Table Of Contents
TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Steering ............... 6-i General Information ..........0A-1 Precautions .............. 6-1 Maintenance and Lubrication ......... 0B-1 Steering General Diagnosis ........6A-1 Steering Wheel and Column ........6B-1 Engine .................
Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Air Bag Warning ..........00-10 Air Bag System Service Warning ...... 00-10 Precautions............00-1 Fastener Caution..........00-11 Precautions for Vehicles Equipped with a Suspension Caution .......... 00-11 Supplemental Restraint (Air Bag) System ..00-1 Wheels and Tires Caution.........
Page 8: Precautions
• If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 9 Precautions: 00-2 Servicing and Handling • After an air bag (inflator) module has been deployed, the surface of the air bag may WARNING contain a powdery residue. This powder consists primarily of cornstarch (used to Many of service procedures require lubricate the bag as it inflates) and by- disconnection of “A/B”...
Page 10 00-3 Precautions: • Even when the accident was light enough not to WARNING cause air bags to activate, be sure to inspect system parts and other related parts according to instructions • For handling and storage of a SDM, select under “Repair and Inspection Required after Accident a place where the ambient temperature in Section 8B”.
Page 11: General Precautions
Precautions: 00-4 General Precautions • Be sure to observe following instructions S7RW0A0000002 when handling service materials such as The WARNING and CAUTION describe some general fuel, oil, fluid, coolant, grease, sealant, precautions that you should observe when servicing a thread lock cement, etc. Otherwise, your vehicle.
Page 12 When use of a certain type of lubricant, bond or reconnecting the battery, connect the positive cable sealant is specified, be sure to use the specified type. first and then the negative cable, and replace the terminal cover. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 I2RH01010030-01...
Page 13: Warning For Wheel (With Tire) Removal
Precautions: 00-6 • Be sure to use special tools when instructed. Special tool (A): 09917–98221 (B): 09916–58210 I2RH01010034-01 • Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. I2RH01010031-01 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly.
Page 14: Precautions In Servicing 4Wd Model
00-7 Precautions: Precautions in Servicing 4WD Model • When testing with 2-wheel brake tester, be S7RW0A0000004 sure to observe the following instructions. CAUTION Otherwise, drivetrain damage and personal injury may result. • Never perform any of the following [A], [B] –...
Page 15: Precautions For Installing Mobile Communication Equipment
Precautions: 00-8 Precautions for Installing Mobile Precautions for Electrical Circuit Service S7RW0A0000008 Communication Equipment • When replacing a fuse, make sure to use a fuse of the S7RW0A0000006 When installing mobile communication equipment such specified capacity. Use of a fuse with a larger capacity as CB (Citizens-Band)-radio or cellular-telephone, be will cause a damage to the electrical parts and a fire.
Page 16 00-9 Precautions: • When connecting connectors, also hold connectors • Be careful not to touch the electrical terminals of parts and put them together until they lock securely (a click which use microcomputers (e.g. electronic control unit is heard). like as ECM, PCM, P/S controller, etc.). The static electricity from your body can damage these parts.
Page 17: Air Bag Warning
Never connect probe where male terminal is only by an authorized SUZUKI dealer. Refer supposed to fit. to “Air Bag System Components, Wiring and Connectors Location in Section 8B” in...
Page 18: Fastener Caution
00-11 Precautions: Fastener Caution ABS Caution S7RW0A0000011 S7RW0A0000015 CAUTION • When ABS control module is removed / installed, do not use impact wrenches which generate shock or When fasteners are removed, always reinstall impact to avoid damaging sensors in ABS control them at the same location from which they module.
Page 19: Repair Instructions
Precautions: 00-12 Repair Instructions Electrical Circuit Inspection Procedure 4) Using continuity check or voltage check the following S7RW0A0006001 procedure, check the wire harness for open circuit While there are various electrical circuit inspection and poor connection with its terminals. Locate methods, described here is a general method to check abnormality, if any.
Page 20 00-13 Precautions: Voltage Check Short Circuit Check (Wire Harness to Ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect negative (–) cable at battery. check can be used as circuit check. 2) Disconnect connectors at both ends of the circuit to 1) With all connectors connected and voltage applied to be checked.
Page 21: Intermittent And Poor Connection Inspection
Precautions: 00-14 Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S7RW0A0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.
Page 22 00-15 Precautions:...
Page 23: Maintenance And Lubrication
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Evaporative Emission Control System Inspection............0B-7 General Description ..........0A-1 Brake Discs and Pads (Front) Inspection....0B-7 Abbreviations ............0A-1 Brake Drums and Shoes (Rear) Inspection ..0B-7 Symbols .............. 0A-2 Brake Hoses and Pipes Inspection .....0B-8 Wire Color Symbols ..........
Page 24: Electronic Stability Program
0A-1 General Information: General Information General Information General Description Abbreviations S7RW0A0101001 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center GEN: Generator ABS: Anti-lock Brake System GND: Ground AC: Alternating Current GPS: Global Positioning System A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HVAC: Heating, Ventilating and Air Conditioning A/F: Air Fuel Mixture Ratio HC: Hydrocarbons...
Page 25: Differential
WU-TWC: Warm Up Three Way Catalytic Converter Symbols S7RW0A0101002 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
Page 26 0A-3 General Information: There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “GRN”). The dual-colored wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of the wire (“GRN”...
Page 27 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
Page 28: Rear Suspension
0A-5 General Information: Vehicle Lifting Points S7RW0A0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
Page 29: Vehicle Identification Number
General Information: 0A-6 Vehicle Identification Number In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against engine front mounting S7RW0A0101006 The number is punched on the front dash panel in member (1) or rear jacking bracket (2). engine room and it is also attached on the left side of instrument panel depending on the vehicle specification.
Page 30 0A-7 General Information: Component Location Warning, Caution and Information Labels Location S7RW0A0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
Page 31: General Information
General Information: 0A-8 I7RW0A010001-01 1. Air bag label on driver air bag (inflator) module 7. Pretensioner label on seat belt retractor 2. Air bag label on contact coil assembly 8. Side/Curtain air bag label on pillar (both right and left sides) (if equipped) 3.
Page 32: Maintenance Schedule Under Normal Driving
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S7RW0A0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S7RW0A0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
Page 33 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Inspect at first 15,000 km (9,000 miles Brake lever and cable (damage, stroke, operation) (I: only Chassis and body Clutch pedal (travel) Clutch fluid (leakage, level) (I: — —...
Page 34 0B-3 Maintenance and Lubrication: Severe Maintenance Maintenance Maintenance interval condition code operation Every 15,000 km (9,000 miles) or 12 months – B C D – – – – Accessory drive belt Every 45,000 km (27,000 miles) or 36 months Every 7,500 km A –...
Page 35 Maintenance and Lubrication: 0B-4 Accessory Drive Belt Replacement Before draining engine oil, check engine for oil leakage. S7RW0A0206002 If any evidence of leakage is found, make sure to correct Water Pump and Generator Drive Belt defective part before proceeding to the following work. Replace belt with new one referring to “Water Pump / 1) Drain engine oil by removing drain plug.
Page 36 0B-5 Maintenance and Lubrication: 4) Screw new filter on oil filter stand by hand until the Engine oil specification filter O-ring contacts mounting surface. Oil pan capacity: About 3.7 liters (7.8 / 6.5 US / lmp pt.) CAUTION Oil filter capacity: About 0.2 liter (0.4 / 0.3 US / To tighten oil filter properly, it is important to lmp pt.) accurately identify the position at which filter...
Page 37 Maintenance and Lubrication: 0B-6 Exhaust System Inspection S7RW0A0206006 WARNING To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised for other service, check exhaust system as follows: I2RH01140007-01...
Page 38: Inspection
0B-7 Maintenance and Lubrication: Fuel Tank Inspection Brake Discs and Pads (Front) Inspection S7RW0A0206012 S7RW0A0206015 Check fuel tank damage, cracks, fuel leakage, corrosion 1) Remove wheel and caliper but don’t disconnect and tank bolts looseness. brake hose from caliper. If a problem is found, repair or replace. 2) Check front disc brake pads and discs for excessive wear, damage and deflection.
Page 39: Brake Hoses And Pipes Inspection
Maintenance and Lubrication: 0B-8 Brake Hoses and Pipes Inspection 2) Check tooth tip of each notch for damage or wear. If S7RW0A0206017 any damage or wear is found, replace parking lever. Perform this inspection where these is enough light and 3) Check parking brake lever for proper operation and use a mirror as necessary.
Page 40: Tires Inspection
0B-9 Maintenance and Lubrication: Tires Inspection Suspension System Inspection S7RW0A0206021 S7RW0A0206024 1) Check tires for uneven or excessive wear, or • Inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on damage. If defective, replace. Refer to “Irregular and/or Premature Wear sleeves;...
Page 41: Drive Shaft (Axle) Boots Inspection
Maintenance and Lubrication: 0B-10 Propeller Shaft (4WD) Inspection 2) Check bolts and nuts for tightness and retighten them as necessary. Repair or replace defective S7RW0A0206027 1) Check propeller shaft connecting bolts for parts, if any. looseness. If looseness is found, tighten to specified 3) Check steering linkage for looseness and damage.
Page 42: Transfer Oil Inspection (4Wd)
0B-11 Maintenance and Lubrication: Transfer Oil Inspection (4WD) HVAC Air Filter (If Equipped) Replacement S7RW0A0206033 S7RW0A0206039 Check transfer oil for leakage, contamination and level Replace HVAC air filter with new one referring to “HVAC referring to “Transfer Oil Level Check in Section 3C”. Air Filter Removal and Installation (If Equipped) in Section 7A”.
Page 43: Specifications
Maintenance and Lubrication: 0B-12 Clutch (for Manual Transaxle) Steering Check for the following. • Check to ensure that steering wheel is free from • Clutch is completely released when depressing clutch instability, or abnormally heavy feeling. pedal, • Check that the vehicle does not wander or pull to one •...
Page 44: Special Tools And Equipment
0B-13 Maintenance and Lubrication: Special Tools and Equipment Recommended Fluids and Lubricants S7RW0A0208001 Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine oil viscosity.) Engine coolant “Antifreeze/Anticorrosion coolant” (Ethylene glycol base coolant) Brake fluid Refer to reservoir cap of brake master cylinder.
Page 45 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC Clearance ..........1A-26 Troubleshooting for Communication Error Precautions............. 1-1 with Scan Tool Using CAN......1A-26 Precautions for Engine.......... 1-1 DTC Table............1A-32 Engine General Information and Fail-Safe Table..........1A-36 Scan Tool Data ..........1A-38 Diagnosis ..........
Page 46 1-ii Table of Contents DTC P0118: Engine Coolant Temperature DTC P0617: Starter Relay Circuit High ...1A-141 Circuit High .............1A-84 DTC P1510: ECM Back-Up Power Supply DTC P0122: Throttle Position Sensor (Main) Malfunction............1A-143 Circuit Low ............1A-87 DTC P2101: Throttle Actuator Control Motor DTC P0123: Throttle Position Sensor (Main) Circuit Range / Performance......1A-144 DTC P2102: Throttle Actuator Control Motor...
Page 47 Table of Contents 1-iii Vacuum Hose Inspection ........1B-3 Camshaft Position Control (VVT Variable EVAP Canister Purge Valve Inspection ....1B-3 Valve Timing) System Description ....1D-3 EVAP Canister Inspection........1B-4 Diagnostic Information and Procedures ....1D-5 EGR Valve Removal and Installation (If Compression Check..........1D-5 Equipped)............
Page 48 1-iv Table of Contents Main Bearings, Crankshaft and Cylinder Radiator Cooling Fan Disassembly and Block Removal and Installation .......1D-59 Reassembly ............1F-9 Crankshaft Inspection ........1D-62 Radiator On-Vehicle Inspection and Cleaning ..1F-9 Main Bearings Inspection........1D-64 Radiator Removal and Installation ...... 1F-9 Sensor Plate Inspection ........1D-68 Water Pump / Generator Drive Belt Tension Rear Oil Seal Inspection ........1D-68...
Page 49 Table of Contents 1-v Ignition System Wiring Circuit Diagram....1H-2 Charging System ........1J-1 Component Location ...........1H-3 General Description ..........1J-1 Ignition System Components Location ....1H-3 Battery Description..........1J-1 Diagnostic Information and Procedures....1H-4 Generator Description ......... 1J-2 Ignition System Symptom Diagnosis....1H-4 Diagnostic Information and Procedures .... 1J-3 Reference Waveform of Ignition System.....1H-4 Battery Inspection ..........
Page 50: Precautions
1-1 Precautions: Precautions Engine Precautions Precautions for Engine S7RW0A1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1A”. Precautions in Diagnosing Trouble Refer to “Precautions in Diagnosing Trouble in Section 1A”. Precautions of ECM Circuit Inspection Refer to “Precautions of ECM Circuit Inspection in Section 1A”.
Page 51: Engine General Information And Diagnosis
ECM memory. Such disconnection will erase memorized information in ECM memory. • Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan IYSQ01110001-01 tool or CAN communication OBD generic scan tool. Before using scan tool, read its Operator’s...
Page 52: Precautions For Dtc Troubleshooting
• Before performed trouble shooting, be sure to read the scan tool used. the “Precautions of ECM Circuit Inspection”. – SUZUKI scan tool displays DTC detected by ECM. • When measuring circuit voltage, resistance and/or – CAN communication OBD generic scan tool...
Page 53: Precaution On Can Troubleshooting
Engine General Information and Diagnosis: 1A-3 Precaution on CAN Troubleshooting S7RW0A1100007 CAN schematic and routing diagram : [C] : [D] : [E] I7RW0A110001-03 [A]: Non-Taiwan model [C]: CAN high line (RED) [E]: K-line [B]: Taiwan model [D]: CAN low line (WHT)
Page 54 CAN has a trouble, it is possible to communicate between scan tool and these control modules. Bus check with SUZUKI scan tool SUZUKI scan tool (SUZUKI-SDT) efficiently diagnoses a CAN bus malfunction by “Communication Bus Check” and “Communication Malfunction DTC” under “Bus check”.
Page 55: General Description
Engine General Information and Diagnosis: 1A-5 General Description Statement on Cleanliness and Care Engine Diagnosis General Description S7RW0A1101001 S7RW0A1101002 An automobile engine is a combination of many NOTE machined, honed, polished and lapped surfaces with There are two types of OBD system tolerances that are measured in the thousands of an depending on the vehicle specification.
Page 56 1 driving cycle of the DTC which is • It is possible to communicate via DLC (3) by using not detected in the 2 driving cycle detection logic. only SUZUKI scan tool (2) but also CAN communication OBD generic scan tool. (Diagnostic Freeze Frame Data information can be accessed by using a scan tool.)
Page 57 • Heated oxygen sensor-2 erased unless the power to ECM is shut off for • ECT sensor specified time or it is cleared by SUZUKI scan tool • TP sensor (SUZUKI-SDT) (2).) For further detail of the checking / clearing procedure, •...
Page 58: Data Link Connector (Dlc) Description
OBD CAN Hi line (6) and Low line (3) (CAN line of ISO 15765-4) are used for SUZUKI scan tool (SUZUKI-SDT) (7) or CAN communication OBD generic scan tool to communicate with ECM (included in immobilizer control) and TCM (Transmission Control Module) (for A/T model).
Page 59: Can Communication System Description
Engine General Information and Diagnosis: 1A-9 CAN Communication System Description S7RW0A1101006 ECM (1), ABS / ESP® control module (2), BCM (3), combination meter (4), keyless start control module (if equipped with keyless start control system) (5), 4WD control module (for 4WD model) (6), steering angle sensor (ESP® model) (8), yaw rate / G sensor (ESP®...
Page 60 1A-10 Engine General Information and Diagnosis: ECM Transmission Data Keyless start Combination ESP® control 4WD control control meter module module module Driving cycle active Warm up cycle active Throttle position signal A/C compressor clutch signal A/C refrigerant pressure signal Fuel consumption signal Fuel level signal Odometer signal Engine coolant temperature signal...
Page 61: Air Intake System Description
Engine General Information and Diagnosis: 1A-11 Air Intake System Description S7RW0A1101007 The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3) (for the details, refer to “Electric Throttle Body System Description”.), and intake manifold (4). The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner, distributed by the intake, and finally drawn into each combustion chamber.
Page 62: Electronic Control System Description
1A-12 Engine General Information and Diagnosis: Operation Description ECM (5) detects opening (depressed extent of pedal) of the accelerator pedal based on signal voltage of the APP sensor (1) and using that data and engine operation condition, it calculates the optimum throttle valve opening. On the other hand, it detects the throttle valve opening based on the signal voltage of the throttle position sensor (3) included in the throttle body (2) and compares it with the above calculated optimum throttle valve opening.
Page 63: Engine And Emission Control Input / Output Table
Engine General Information and Diagnosis: 1A-13 Engine and Emission Control Input / Output Table S7RW0A1101010 ELECTRIC CONTROL DEVICE OUTPUT INPUT BAROMETRIC PRESSURE SENSOR BRAKE LIGHT SWITCH START SWITCH IGNITION SWITCH A/C REFRIGERANT PRESSURE SENSOR (if equipped with A/C) BLOWER SWITCH A/C SWITCH (if equipped with A/C) A/C EVAP OUTLET AIR TEMP.
Page 64: Schematic And Routing Diagram
1A-14 Engine General Information and Diagnosis: Schematic and Routing Diagram ECM Input / Output Circuit Diagram S7RW0A1102003 E01-35 E01-45 E01-37 E01-32 E01-52 C01-45 E01-34 C01-44 E01-36 C01-43 E01-51 C01-54 E01-50 C01-40 C01-42 RED/YEL C01-20 C01-41 C01-1 BLU/YEL C01-2 BLU/WHT C01-21 BLK/ORN C01-16 BLU/RED...
Page 65 Engine General Information and Diagnosis: 1A-15 4. CMP sensor 28. Electric throttle body assembly 52. To ABS / ESP® control module 5. CKP sensor 29. Throttle actuator 53. “STOP” fuse 6. HO2S-1 30. TP sensor 54. Main relay 7. HO2S-2 (if equipped) 31.
Page 66 1A-16 Engine General Information and Diagnosis: Connector: C01 Terminal Wire color Circuit Terminal Wire color Circuit BLU/YEL Fuel injector No.1 output — — BLU/WHT Fuel injector No.2 output — — EGR valve (stepper motor coil 2) GRN/ORN — — output EGR valve (stepper motor coil 1) GRN/RED —...
Page 67 Engine General Information and Diagnosis: 1A-17 Connector: E01 Terminal Wire color Circuit Terminal Wire color Circuit BLK/RED Main power supply Ground for ECM Power source for ECM internal Power supply of throttle WHT/RED memory actuator drive circuit. CAN communication line (active high signal) to ABS / ESP®...
Page 68: Engine And Emission Control System Flow Diagram
1A-18 Engine General Information and Diagnosis: Engine and Emission Control System Flow Diagram S7RW0A1102002 I7RW0A110008-02...
Page 69: Engine And Emission Control System Diagram
Engine General Information and Diagnosis: 1A-19 Engine and Emission Control System Diagram S7RW0A1102001 I5RW0C110009-02...
Page 70 1A-20 Engine General Information and Diagnosis: 1. Air cleaner 17. Radiator cooling fan 33. A/C switch (A/C model) 2. EVAP canister purge valve 18. A/C condenser cooling fan 34. A/C evaporator outlet air temp. sensor (manual A/C model) 3. MAF and IAT sensor 19.
Page 71: Component Location
Engine General Information and Diagnosis: 1A-21 Component Location Electronic Control System Components Location S7RW0A1103001 NOTE The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed at the opposite side. I6RW0D110016-03 Information sensors Control devices Others 1.
Page 72: Diagnostic Information And Procedures
1A-22 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine and Emission Control System Check S7RW0A1104001 Refer to the following items for the details of each step. Step Action Customer complaint analysis Go to Step 2. Perform customer complaint analysis. 1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Page 73 Engine General Information and Diagnosis: 1A-23 Step Action Final confirmation test Go to Step 6. End. 1) Clear DTC if any. 2) Perform final confirmation test referring to “Final Confirmation Test”. Is there any problem symptom, DTC or abnormal condition?
Page 74 1A-24 Engine General Information and Diagnosis: Step 1: Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 75: Malfunction Indicator Lamp (Mil) Check
Engine General Information and Diagnosis: 1A-25 Step 2: DTC / Freeze Frame Data Check, Record and Step 11: Final Confirmation Test Clearance Confirm that the problem symptom has gone and the First, check DTC (including pending DTC), referring to engine is free from any abnormal conditions. If what has “DTC Check”.
Page 76: Dtc Clearance
Board Diagnostic (OBD) System”. – TCM – Keyless start control module 1) Connect SUZUKI scan tool or CAN communication OBD generic scan tool to data link connector in the – ESP® control module same manner as when making this connection for –...
Page 77 Engine General Information and Diagnosis: 1A-27 Wiring Diagram L34-3 C06-17 L34-2 C06-7 WHT C01-13 G26-22 RED C01-12 G26-23 E01-3 E01-18 G241-9 G241-6 G241-7 G241-10 E08-12 E08-1 G241-8 E08-2 G241-11 E08-13 G33-9 E04-2 G33-10 E04-1 G04-4 G04-2 G04-3 G16-19 G04-1 G16-18 G26-22 C06-17 G26-23...
Page 78 1A-28 Engine General Information and Diagnosis: 14 13 12 11 10 9 8 7 24 23 18 17 3938 32 31 3938 32 31 5453 5453 47 46 47 46 18 17 13 12 39 38 33 32 31 30 29 28 27 24 23 18 17...
Page 79 Engine General Information and Diagnosis: 1A-29 Troubleshooting Step Action Scan tool check Go to Step 2. Scan tool faulty. Refer to its operator’s manual. 1) Disconnect scan tool from DLC with ignition switch turned OFF. 2) Check for proper connection to all terminals of scan tool connector.
Page 80 1A-30 Engine General Information and Diagnosis: Step Action CAN line check between DLC and BCM Go to Step 6. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect BCM connector from BCM. 3) Check for proper connection to all terminals of BCM connector.
Page 81 Engine General Information and Diagnosis: 1A-31 Step Action CAN line check Go to Step 8. Repair CAN line. 1) Turn ignition switch to OFF position. 2) Disconnect connectors of all control module / sensor communicated by CAN. 3) Check all the following CAN lines for open, short to power circuit, short to ground circuit, short to other CAN line and high resistance.
Page 82: Dtc Table
1A-32 Engine General Information and Diagnosis: DTC Table S7RW0A1104006 NOTE • There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. • For non-Euro-OBD model, some of DTC No. with delta ( ) mark in the following table can not be detected by ECM depending on vehicle specification.
Page 83 Engine General Information and Diagnosis: 1A-33 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Engine coolant temperature circuit 1 driving *P0117 Circuit voltage of ECT sensor is less than specification. cycle Engine coolant temperature circuit 1 driving *P0118 Circuit voltage of ECT sensor is more than specification.
Page 84 1A-34 Engine General Information and Diagnosis: Detecting condition DTC No. Detecting item (DTC will set when detecting:) Catalyst system efficiency below 2 driving Output waveforms of HO2S-1 and HO2S-2 are similar. *P0420 threshold cycles Evaporative emission system purge Monitor signal of EVAP canister purge valve is different 2 driving *P0443 control valve circuit...
Page 85 Engine General Information and Diagnosis: 1A-35 Detecting condition DTC No. Detecting item (DTC will set when detecting:) Difference between the opening angle based on Pedal position sensor (main / sub) accelerator pedal position sensor (main) and the opening 1 driving *P2138 voltage correlation angle based on accelerator pedal position sensor (sub) is...
Page 86: Fail-Safe Table
1A-36 Engine General Information and Diagnosis: For Vehicle Equipped with A/T NOTE There are two types of OBD system depending on the vehicle specification. For identification, refer to “Precaution on On-Board Diagnostic (OBD) System”. When using CAN communication OBD generic scan tool, not only the previous star (*) marked ECM DTC(s) but also the following DTC(s) is displayed on CAN communication OBD generic scan tool simultaneously.
Page 87 Engine General Information and Diagnosis: 1A-37 DTC No. Detected item Fail-safe operation • ECM turns off throttle actuator control relay and throttle valve is fixed at the opening of about 7° from its completely closed position (default P0122 Throttle position sensor (main) circuit low opening).
Page 88: Scan Tool Data
1A-38 Engine General Information and Diagnosis: Scan Tool Data S7RW0A1104009 As the data values are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each specified data range.
Page 89 Engine General Information and Diagnosis: 1A-39 Normal condition / Scan tool data Vehicle condition reference values SHORT FT B1 At specified idle speed after warming up –20 – +20% (SHORT TERM FUEL TRIM) LONG FT B1 At specified idle speed after warming up –20 –...
Page 90 1A-40 Engine General Information and Diagnosis: Normal condition / Scan tool data Vehicle condition reference values Engine coolant temp.: lower RADIATOR FAN than 97.5 °C (207.5 °F) (RADIATOR COOLING FAN Ignition switch ON Engine coolant temp.: 100 CONTROL RELAY) °C (212 °F) Blower motor switch and A/C A/C COND FAN switch turned ON/ECT over...
Page 91 Engine General Information and Diagnosis: 1A-41 Scan Tool Data Definitions FUEL SYSTEM B1 (FUEL SYSTEM STATUS) Air/fuel ratio feedback loop status displayed as one of COOLANT TEMP (ENGINE COOLANT TEMPERATURE, °C, °F) the followings. OPEN: Open-loop has not yet satisfied conditions to go It is detected by engine coolant temp.
Page 92 1A-42 Engine General Information and Diagnosis: A/C COND FAN (A/C CONDENSER COOLING FAN CANIST PRG DUTY (EVAP CANISTER PURGE FLOW DUTY, %) CONTROL RELAY, ON/OFF) This parameter indicates valve ON (valve open) time ON: Command for A/C condenser cooling fan control rate within a certain set cycle of EVAP canister purge relay operation being output.
Page 93: Visual Inspection
Engine General Information and Diagnosis: 1A-43 INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH, THROTTLE MOTOR RELAY (ON/OFF) ON: Throttle actuator (motor) control activated by ECM. msec.) OF: Throttle actuator (motor) control stopped by ECM. This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (but injector VEHICLE SPEED (km/h, mph) drive time of NO.1 cylinder for multiport fuel injection).
Page 94 1A-44 Engine General Information and Diagnosis: Step Action Check keyless start control system malfunction Go to Step 5. Keyless start control system malfunction. 1) Check keyless start control system referring to “Keyless Start System Operation Inspection in Section 10E”. Is check result satisfactory? Is engine cranked? Go to Step 6.
Page 95: Engine Symptom Diagnosis
Engine General Information and Diagnosis: 1A-45 Engine Symptom Diagnosis S7RW0A1104012 Perform troubleshooting referring to the followings when ECM has detected no DTC and no abnormality has been found in “Visual Inspection” and “Engine Basic Inspection”. Condition Possible cause Correction / Reference Item Hard starting (Engine Faulty spark plug “Spark Plug Inspection in Section 1H”...
Page 96 1A-46 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noise – Valve Improper valve lash “Camshaft, Tappet and Shim Inspection in noise Section 1D” Worn valve stem and guide “Valves and Valve Guides Inspection in NOTE Section 1D”...
Page 97 Engine General Information and Diagnosis: 1A-47 Condition Possible cause Correction / Reference Item Engine overheating Inoperative thermostat “Thermostat Inspection in Section 1F” Poor water pump performance “Water Pump Inspection in Section 1F” Clogged or leaky radiator “Radiator On-Vehicle Inspection and Cleaning in Section 1F”...
Page 98 1A-48 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Excessive engine oil Sticky piston ring “Cylinders, Pistons and Piston Rings consumption – Oil Inspection in Section 1D” entering combustion Worn piston and cylinder “Cylinders, Pistons and Piston Rings chamber Inspection in Section 1D”...
Page 99 Engine General Information and Diagnosis: 1A-49 Condition Possible cause Correction / Reference Item Excessive detonation – Faulty spark plug “Spark Plug Inspection in Section 1H” Engine makes Loose connection of high-tension cord “High-Tension Cord Removal and Installation continuously sharp in Section 1H” metallic knocks that Engine overheating Condition “Engine overheating”...
Page 100 1A-50 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Improper engine idling or Faulty spark plug “Spark Plug Inspection in Section 1H” engine fails to idle Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation in Section 1H”...
Page 101 Engine General Information and Diagnosis: 1A-51 Condition Possible cause Correction / Reference Item Excessive hydrocarbon Faulty spark plug “Spark Plug Inspection in Section 1H” (HC) emission or carbon Leaky or disconnected high-tension cord “High-Tension Cord Removal and Installation monoxide (CO) in Section 1H”...
Page 102: Malfunction Indicator Lamp Does Not Come On With Ignition Switch On And Engine Stop (But Engine Can Be Started)
1A-52 Engine General Information and Diagnosis: Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) S7RW0A1104013 Wiring Diagram C01-13 C01-12 E01-3 E01-18 RED/BLK BLK/ORN G241-31 G241-16 BLK/YEL BLK/WHT E01-29 C01-58 BLK/ORN C01-15 C01-30...
Page 103 Engine General Information and Diagnosis: 1A-53 Troubleshooting NOTE • Before performed trouble shooting, be sure to read the “Precautions of ECM Circuit Inspection”. • When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect the special tool to ECM and/or the ECM connectors referring to “Inspection of ECM and Its Circuits”. Step Action MIL power supply check...
Page 104: Malfunction Indicator Lamp Remains On After Engine Starts
1A-54 Engine General Information and Diagnosis: Malfunction Indicator Lamp Remains ON after Engine Starts S7RW0A1104014 Wiring Diagram Refer to “Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)”. Circuit Description When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point).
Page 105: Dtc P0010: Camshaft Position Actuator Circuit (For Engine With Vvt System)
Engine General Information and Diagnosis: 1A-55 DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system) S7RW0A1104015 System and Wiring Diagram GRN/RED C01-60 C01-58 BLK/ORN C01-59 GRN/WHT C01-15 C01-30 E01-31 [A]: 39 38 32 31 39 38 32 31 54 53 47 46 54 53...
Page 106 1A-56 Engine General Information and Diagnosis: DTC Troubleshooting NOTE Before this troubleshooting is performed, read the precautions for DTC troubleshooting referring to “Precautions for DTC Troubleshooting”. Step Action Was “Engine and Emission Control System Check” Go to Step 2. Go to “Engine and performed? Emission Control System Check”.
Page 107: Dtc P0011 / P0012: Camshaft Position - Timing Over-Advanced Or System Performance / Retarded (For Engine With Vvt System)
Engine General Information and Diagnosis: 1A-57 Step Action Oil control valve check Substitute a known- Faulty oil control valve. Check oil control valve referring to “Oil Control Valve good ECM and recheck. Inspection (For Engine with VVT) in Section 1D”. Is resistance within specified value? DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system)
Page 108 Installation in Section temperature. 1D”. If OK, go to Step 5. 3) Select menu to “Data List”. 4) Check that “VVT GAP” displayed on SUZUKI scan tool is 0 – 3°. Is it OK? Camshaft position control check Substitute a known- Go to Step 5.
Page 109: Dtc P0031 / P0032: Ho2S Heater Control Circuit Low / High (Sensor-1)
Engine General Information and Diagnosis: 1A-59 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) S7RW0A1104017 Wiring Diagram BLK/WHT E01-29 BLK/WHT BLK/RED C01-46 C01-10 C01-57 39 38 32 31 39 38 32 31 54 53 47 46 54 53 47 46 I6RW0D110020-01...
Page 110 1A-60 Engine General Information and Diagnosis: Step Action HO2S-1 heater power circuit check Go to Step 3. “BLK

Suzuki SX4 Service Manual

Table of Contents

Section 0 General Information

Section 1 Engine

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Troubleshooting

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Summary of Contents for Suzuki SX4